In February of 2002, the United States Steel Corporation(U.S. Steel) and TECO-Westinghouse Motor Company(TWMC) began discussions involving outfitting the IrvinWorks Cold Reduction Mill withmodern DC motors.

After evaluating plans to meetthe cold mill’s present and futurerequirements, TWMC presenteda strategic solution to design andbuild nine advanced 4500 HPDC cold mill motors at theTWMC plant in Round Rock,Texas, to replace each of the nineexisting motors at the IrvinWorks mill located in Pittsburgh.

The existing main-drive DCmotors were rated at 4000 HP,200/500 RPM and required

weekly outages for inspection and repair.Improvements realized from the installation of the new

TWMC DC motors will allow the Irvin Works ColdReduction Mill to more efficient-ly roll a greater range and gaugeof coils. The upgrade will alsomaximize production reliabilityand profits for the mill.

In August of 2002, TWMCbegan the design and manufac-ture of nine new drop-in replace-ment DC cold mill motors for allfive mill stands. The new 4500HP DC motors will provide a fargreater thermal margin and stillutilize the mill’s existing ventila-tion system.

Continued on page 2

Modern DC Motors Maximize Cold Mill Production Reliability, Profits

TORQUE REPORTINSIDE THIS ISSUE:INSIDE THIS ISSUE:

TORQUE REPORT 1

* NAQN Hails TWMC Crusher Motor .... 2

* Repair Saves Air Separation Plant

Time, Money ................................ 2

* EASA Convention Update ............. 3

* GA7200 “Out-performs” for

Demanding Applications .............. 3

* TWMC Record Low LTAs ............... 3

* EPRI Seminar Follow-up .............. 3

* R & D Spotlight ............................ 4

* TECO Tech Tip .............................. 4

* Wk2 vs. Gd2 ................................... 4

* Ash Grove Wound Rotor Project ... 5

* New Product Expansions ............. 5

* Water Shortage Crisis: TWMC

Called to Duty .............................. 5

TORQUE REPORTSEPTEMBER 2003SEPTEMBER 2003

TWMC is designing and manu-facturing nine advanced modernDC cold mill motors for the IrvinWorks Cold Reduction Mill.Above: This single armature 4500HP TWMC DC motor wasinstalled into Stand 1 at the IrvinWorks Cold Mill in Pittsburgh inJune of this year. Left: One of theTWMC advanced 4500 HP DCarmatures prior to shipment tothe customer. Right: One of the9000 HP double armature DCcold mill motors undergoing fac-tory testing at the TWMC plant inRound Rock, Texas.

TWMC Selected as Shell Pipeline‘Tier One Motor Supplier’

Shell Pipeline Company LP, a wholly-owned subsidiary ofShell Oil ProductsUS, recently namedTECO-WestinghouseMotor Co. (TWMC)as their Tier Onemotor supplier. After extensive tech-

nical and commercialreview, an agreement

was reached that designates TWMC as theprimary supplier ofmedium voltageinduction motors.The agreement alsoallows TWMC toassist Shell PipelineCompany LP withengineering serviceresources.

Continued on page 2

TORQUE REPORT2

Editorial Statement: “Torque Report” is a periodical publication of TECO-Westinghouse Motor Company. Its editorial mission is to inform our readership in the areas of motor application industries,as well as business and world affairs that have an impact on our mutual concerns. Comments, inquiries and suggestions should be directed to: Torque Report, TECO-Westinghouse Motor Company,

5100 N. IH-35, Round Rock, TX 78681 USA. Phone: 1-800-451-8798. FAX: 512-244-5512. E-mail: torquereport@tecowestinghouse.com. Website: www.tecowestinghouse.com.

The new cold mill motors fea-ture an advanced, fully equalizedarmature winding, in conjunctionwith TWMC's “Balanced Spring”V-Ring commutators and highfatigue strength risers.

In addition, the advanced insu-lation systems of both the arma-ture and stator insure reliable and

long-lasting performance in the harshest steelmill environments.

The motor for the first stand in the serieswas installed in June of this year and is meet-ing all performance expectations of the IrvinWorks Cold Reduction Mill operations team.

Modern DC Motors MaximizeCold Mill Reliability, ProfitsContinued from page 1

Above: TWMC is installing upgraded DC cold mill motorsfor each of the nine existing DC motors inside the IrvinWorks Cold Reduction Mill. Above left: Modern commu-tator and brush holder assemblies.

North American Quarry News (NAQN), a "rock-to-road trade magazine,"dedicated its back cover and first feature article to TWMC this June.

The feature focused on K.R.C. Aggregate, Inc., a producer of aggregates forthe construction industry, and its success with TWMC motors. K.R.C. pur-chases its motors from TWMC distributor, Industrial Electrical Company.

“For around 90% of the equipment I order, I'll request that they come withTECO-Westinghouse motors because [they] last much longer than the otherswe've tried,” Kelly Isaman, K.R.C. plant operations supervisor, told NAQN.

NAQN Editor-in-Chief, Cuyle Rockwell called the article “a powerful testi-monial” to the quality of TWMC motors. “When a quarry operation clearlydemonstrates its confidence in your products…it is viewed as impartial and insome ways more reliable than an advertisement alone” he wrote by e-mail.A separate sidebar on the same page highlighted TWMC's history, growth and

its success based on technological versatility. The fanfare concluded with afull-page ad, in color, on the back cover of NAQN.

The articles are posted on NAQN’s website at www.quarrynews.com.

NAQN Hails TWMC Crusher Motor

TWMC: Tier One ShelTWMC: Tier One ShelllSupplSupplierier Continued from page 1

As part of the technical support package,TWMC designed and provided engineeringdata for over 30 induction motor ratings withspeeds of 1200 RPM to 3600 RPM.

With mechanical and electrical informationreadily available to Shell Pipeline Companyunits across the country, maintenance andengineering personnel and operators will beable to quickly determine the motor that bestsuits their replacement or new equipmentapplication.

Operating approximately 13,000 miles ofpipelines in 22 states, Shell PipelineCompany's pipelines move over seven mil-lion barrels of crude oil and refined productseach day.

TWMC recently repaired a 14,000HP, 6 pole, high-voltage synchro-nous motor for a large air separationplant. Forced to shut down, the plantwas losing significant revenue as aresult of the motor failure.

TWMC activated ateam of shoprepair personneland key supportfunctions torespond effi-ciently to theemergency. Afield serviceengineer wasdispatched to theplant site per thecustomer’s request.Subsequent site testingexposed problems with thewound field poles on the rotor.

The nine-year-old motor was dis-mantled and shipped to TWMC inRound Rock, Texas for a “full over-time” repair. Upon the arrival of themotor, customer representatives wit-nessed the removal of the woundpoles by TWMC shop personnel,who assessed the damage.

Testing at TWMC revealed four

grounded and shorted poles thatrequired re-insulation. TWMCarranged for the re-insulation of thepoles, and the remainder of themotor was reconditioned while thepoles and coils were repaired.

Upon completion of repairs to thepole components,TWMC shop per-sonnel spent the

weekend assembling therotor with the newly insulated polesand performing all necessary testing.All tests were completed successful-ly, including additional tests per-formed at the customer's request.

The motor repair was completedand shipped back to the customersite four days ahead of schedule, anda TWMC field service engineer waspresent for the motor re-assemblyand on-site testing.

TWMC Repair Saves Time, Moneyfor Air Separation Plant

The 14,000 HP,6 pole, synchronous

motor was repaired fourdays ahead of schedule.

TWMC presented new products tocurrent distributors who wereamong the 2000+ attendees atthe Electrical ApparatusService Association (EASA)Convention in San

Francisco, CA fromJune 29 - July 1, 2003.

“We highlighted the expansion of our con-trols product line and our new crusher motor,the MAX-HT,” said Wes Winter, GeneralManager for Stock Products.

In addition to thanking current distributorsfor their partnership, TWMC unveiled its new logo at the convention.

From July 15-17, 2003, TWMChosted an Electric PowerResearch Institute (EPRI) spon-sored Motor and GeneratorRewind Seminar at the TWMCplant in Round Rock, Texas. Atotal of 44 pre-registered partici-pants attended the three-day sem-inar conducted by Jim Oliver ofJARSCO Engineering and EltonFloyd of TXU, with additionaltopics taught by conference attendeeHugh Zhu of Powertech Labs andTWMC engineers.

In addition to covering an extensivelist of motor and generator repair topicsin the seminar sessions, attendees were

given a guided tour of the TWMC man-ufacturing and repair facility.

Seminar participants represented 22different companies and were from 11states - Arkansas, Arizona, California,Kansas, Louisiana, Mississippi, North

Carolina, Ohio, Pennsylvania,Texas and Washington - and theCanadian province of BritishColumbia. According to Oliver,this seminar attracted the highestattendance of any Motor-Generator Rewind Seminar thusfar in the history of EPRI spon-soring the event.

Attendees represented a widevariety of industries, including the

petrochemical, electric utility, andmotor-generator repair and serviceindustries. U.S. government test andresearch facility representatives andindustry consultants were also amongthose who attended.

EASA Convention:Golden Gate to Success

TORQUE REPORT 3

Magnum, a drives and controls original equipmentmanufacturer in California, is co-owned by PatMulligan and Dave Sandy.

Mulligan and Sandy first heard of TWMC a fewyears ago when a TWMC customer mentioned thatthey had switched to TWMC drives and were verypleased with the results. Magnum then made theirown inquiries,and as a result,started usingTWMC drivesfor all of theirnew customersin 2002.

“Our applica-tions are verydemanding. Weneed a strong,reliable drivethat can deliverlow-end torquewith rapidr e s p o n s e , ”Mulligan said,“and frankly there are only a few drives on the mar-ket that can supply that.”

Among the TWMC products, Magnum uses theGA7200 drives in situations where they do not needa vector drive.

“The GA7200 has plenty of torque and a rapidresponse time,” Mulligan said. “When evaluated ona price per HP basis, it out-performs any similardrive on the market.”

TWMC meets distributors at theEASA Convention in San Francisco.

EPRI seminar attendees stand in front of a 60,000 HP rotor shaft at theTWMC factory. Forty-four participants attended the three-day event.

GA7200 “Out-performs” forDemanding Applications

Strong and reliable, the GA7200 generalpurpose inverter delivers the low-end torquewith rapid response that Magnum needs.

As of August 31, 2003, TWMChas had no Lost Time Accidents(LTAs) for 430 days.

As shown in the graph at theright, TWMC’s incident rate for2003 (through August) is 3.33,an improvement from TWMC’s4.2 incident rate for 2002.

The industry average incidentrate for Motors and Generators(SIC Code 3621)* is 6.5.

* Industry statistics are from the Bureau of Labor andStatistics’ website (www.bls.gov), with the most cur-rent numbers being from the year 2001.

IncidentRatios

2001 2002 2003

5.78

6.5

4.2

6.5

3.33

6.5

Injury Comparisons

TWMC Record Low LTAs

Overall-TWMC

Overall-Industry

Peak Attendance at 2003 EPRI Motor-Generator Rewind Seminar

TECO Electric and MachineryCo., Ltd. (TECO) has expandedits Research and Development(R&D) capacity to form a newGlobal Motor R&D Center.The expansion began in 2003and will increase TECO's com-petitive market position in themotor business. The mission ofthe new center is to lead thecompany to the forefront of themotor industry with new con-cepts and technology.

The Global Motor R&D Center is headquartered at the TECO-WestinghouseMotor Company (TWMC) plant in Round Rock, Texas, and is divided into threeCenter of Excellence groups located in Round Rock, Taipei, Taiwan and Wuxi,China. The three groups are supported by TECO's global consulting network, andwork together daily utilizing TWMC’s video conferencing capabilities.

“TECO is in an excellent position to tackle the most complex disciplines andtechnical challenges of rotatingmachines,” said Dr. George Gao,Director of R&D. Six Sigma certified,Dr. Gao holds a Ph.D. in electrical insu-lation engineering, and has over 20years of experience in rotating machinedevelopment.

The R&D centers boast comprehen-sive capabilities in rotating machinedevelopment with a staff of over 20experienced, highly-qualified engineersand developers, including Ph.D.-levelresearchers in electrical, mechanical,thermal management and insulationsystem engineering. The centers utilizeadvanced engineering modeling soft-ware packages such as Magsoft, Ansysand Fluent, as well as an advancedmaterials lab with capabilities thatexceed all industrial test requirements.

Using these resources, the GlobalMotor R&D team is poised to lead theindustry by inventing new concepts andtechnologies while improving perform-ance in existing products. The team isdeveloping new products, processesand materials to extend TWMC's com-petitive edge and will actively con-tribute to customer technical supportand industrial standards development.

With the support of top managementand the abundance of resources, theTECO Global Motor R&D team isready to overcome any challenge.

Spotlight: TECO Global MotorResearch and Development Center When re-greasing a motor, do

not fill the cavity more than30% with grease. If the greasecannot run off, the resistanceto rolling caused by the exces-sive grease will result inhydraulic locking in thebearing, particularlyduring periods ofrapid acceleration.

TECO Tech Tip

ConverConverting ting WkWk22 values to Gdvalues to Gd22 values:values:

Wk2 (lbf-ft2) / 5.93 = Gd2 (kgm-m2)where

1 kgf = 2.205 lbf,1 kgm produces 1 kgf, and

1 m2 = 10.764 ft2

Gd2 is larger by a factor of 4 since d = (k/2),and d is then squared. Therefore

2.205 * 10.7644

= 5.93

FEA study on a rotor spider with thermal and mechanicalstress analysis.

Gd2 is used in European countries torepresent a body's resistance to changesin rotational speed. Wk2 is more widelyused in North America, but it expressesthe same physical property as Gd2.

The primary difference between Gd2

and Wk2 is that Gd2 is calculated usingthe diameter of gyration instead of theradius of gyration. When the diameterof gyration is squared, the value willchange the number by a factor of 4 rel-ative to Wk2.

Gd2 is also a mass-based quantity,while Wk2 is a weight-based quantity.The units of Gd2 are expressed in kgm-m2, while the units of Wk2 are lbf-ft2.

It is important for end users to under-stand the difference between the twoquantities. Consider the case where acustomer specifies a load inertia as aWk2 quantity but it is actually a Gd2

quantity. The motor vendor mightdesign a motor for a load inertia manytimes larger than what the customeractually needs.

This issue can be avoided by payingcareful attention to units in which theload inertia is reported and by insistingthat the number reported is accompa-nied by the units.

Top: Electromagnetic Field Analysis for a four polemotor. Middle: Dynamic analysis for a motor fan.Bottom: Materials testing section of the R&D lab.

Wk2 vs. Gd2

TORQUE REPORT4

TWMC recently announced the expansion ofthe GA7200 and the FM50 product lines.

The GA7200 AC driveline has been expandedthrough 450 HP constanttorque. Utilizing the lat-est in electrical design,these high HP drives aresome of the most com-pact in the industry. Thedrives are offered in astandard NEMA 1enclosure or as a custompackage drive built tocustomer specifications.

The FM50 AC drive is now available in aNEMA 4X enclosure which comes in twostyles - Keypad Only and Keypad withOperator Devices. The Keypad Only modelallows control via the keypad or remote controlsignals. The Keypad withOperator Devices model isdesigned for local controlof the drive, and includesthe digital keypad, linedisconnect, speed poten-tiometer and a forward-off-reverse switch.

TWMC recently supplied AshGrove Cement Company'sForeman plant with a new 4500HP, 514 RPM, 4000 Volt woundrotor motor. The motor, manufac-tured at TWMC's Round Rock,Texas plant, was a replacementmotor for an existingWestinghouse wound rotor motorthat has been operating success-fully since the 1960s. With aseries of protective upgrades tothe design, the new TWMCwound rotor motor will save thecompany considerable time andcosts over the next few decades.The largest American-owned cement

company in the U.S., Ash Grove com-missioned Westinghouse Electric Co. inthe 1960s to build a wound rotor induc-

tion motor to drive its ball mill. Thisyear, TWMC engineers upgraded thevintage design, adapting it to the dustyenvironment of the cement mill. Intakefilters and exhaust screens were added

and as a second defense, abrasiontreatment was applied to the motorwindings to protect it from harm-ful dust and other abrasive materi-als. The sliprings were also enclosedto protect operators from injury.

Protecting these critical motorparts increases the expected lifeand efficiency of the motor with-out requiring constant shutdownsfor maintenance. At ten feet highand 12 feet long, the 4500 HPmotor ranks among the largestwound rotor motors produced byTECO-Westinghouse. The mill islocated in Foreman, Arkansas, and

is one of nine cement plants operatingin the Ash Grove system, which aresome of the most efficient and bestmaintained in the country.

TORQUE REPORT 5

The new TWMC 4500 HP, 514 RPM, 4000 Volt wound rotor motor atAsh Grove Cement’s Foreman plant.

Stock GrStock Group: Newoup: NewPrProduct Expansionsoduct Expansions

Water Shortage Crisis:TWMC Called to Duty

When water shortages gripped theLas Vegas valley, TWMC wasthere. This September,TWMC will ship fivesynchronous, horizontalmotors to Henderson,Nevada, for installation atthe River Mountain WaterTreatment Facility. The3500 HP, 900 RPM motorswill operate five pumpsat the newly construct-ed pump station -each pump with acapacity of moving34 million gallonsof water per day.“This TWMC project contributes to the sub-

stantial base of motors - including over 20 large motors in the past fiveyears - built for the Southern Nevada Water Authority (SNWA),” saidJames Janik, Team Leader of Special Products at TWMC.

The River Mountain pump station, owned by SNWA, will supply freshwater pumped out of Lake Mead for the growing population of the LasVegas valley.The recent influx of Las Vegas residents has forced SNWA to add anoth-

er facility in addition to the existing Alfred Merritt Smith WaterTreatment Facility. Another major drain of water comes from 25 south-ern Nevada golf courses, which the state’s government recently subject-ed to a stringent drought plan, beginning September 1, 2003.

Motor Makeover Replacement Raises Cement Mill Efficiency

TWMC Introduces New Look

IEEE-PCIC Conference50th Anniversaryin Houston, TX!

September 15 - 17, 2003Westin Galleria Hotel

TTORQUEORQUE RREPORTEPORTSSEPTEMBEREPTEMBER 20032003

5100 N. IH-35Round Rock, TX 78681

1-800-451-8798

If you are interested in receiving futureissues of TTORQUEORQUE RREPORTEPORT, please visit

www.tecowestinghouse.com/torquereport.htmor send an e-mail to

torquereport@tecowestinghouse.com.

Power Project a Sweeping Success

TWMC introduced its new logo inJune at the EASA Convention in SanFrancisco, CA. The logo is a result of anew corporate identity system passeddown from its parent company, TECOElectric & Machinery Co., Ltd. (Taipei,Taiwan). It was developed to highlightthe TECO Group's efforts toward con-tinual improvement.

The new symbol exemplifies themomentum of the TECO Group as theyexpand to new global horizons and is atotem signifying TECO's core business,the electric motor. The TECO Groupwill aim at expanding international

horizons and broadening global net-works to boost TECO's internationalbrand recognition.

Through diversified operation,TECO's businesses expand across vari-ous areas including heavy electricalmotors, home appliances, IT systems,telecommunications, electromechanicalcomponents, key components, infra-structure, financial investment, foodservices, and distribution industries.

As of the end of fiscal year 2001,TECO Group's total revenue fromworldwide operations has reachedUS$3 billion.

TWMC recently performed a success-ful sweep of Florida Power and LightCompany’s (FLP) latest expansionproject. In the project, FLP will addanother 1,900 megawatts of generatingcapacity by expanding at its existingManatee and Martin county sites tomeet future demand and reserve marginrequirements.

For the project, TWMC willbuild approximately 90% ofthe medium voltage, induc-tion motors required - 43motors in all.

TWMC’s motors will be manufacturedfor six different applications includingboiler feed, circulating water, auxiliarycooling water and condensate pumps,and cooling tower fans. Ratings for themotors range from 200 to 3600 HP.

FPL serves approximately 3.9 millioncustomer accounts in Florida. Theongoing plant development included inthis project will allow FPL to provide

electricity for600,000 newcustomers by

2005.

Come see us at theseupcoming conferences:

AISE Conventionin Pittsburgh, PA!

September 28 - October 2, 2003Booth 1655

Pleaseinsert BulkRate Permit

# here.